Optical Connector Light-Turning Ferrule Window Design
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Solution Overview
Problem
Current fiber optic connectors with light-turning optical ferrules lack access points for testing, inspection, or cleaning without removing the ferrules, and stacked configurations often block light output from one ferrule by the next, preventing detection.
Innovation Solution
An optical connector design featuring a housing with a window for light output from the ferrule, allowing redirected light to exit through the bottom surface and exit the housing, with a mating ferrule preventing further light exit when mated, and optionally a sliding cover for sealing the window.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical ferrules are enclosed in housing without access points, then protection and structural integrity are improved, but accessibility for testing, inspection, or cleaning deteriorates
Solution Approach 1:
The housing is segmented with a removable cap portion that can be separated from the base, creating an access point to the interior cavity while maintaining structural integrity when closed. This allows the housing to provide protection during normal operation while enabling accessibility when needed.
Solution Approach 2:
A removable cap acts as an intermediary element between the housing and the optical ferrules, providing controlled access to the interior cavity. The cap can be removed to allow testing, inspection, or cleaning of the ferrules while remaining in place during normal operation to maintain structural integrity.
2Productivity
If multiple optical ferrules are stacked in housing, then device density is improved, but light output from individual ferrules is blocked by adjacent ferrules
Solution Approach 1:
The optical ferrules are arranged in a vertical stack along the vertical dimension, with light directed horizontally through side-facing output surfaces. This dimensional arrangement allows multiple ferrules to be densely packed vertically while their light outputs exit laterally without blocking each other.
Solution Approach 2:
Each optical ferrule is positioned with its light output surface facing a different lateral direction (e.g., first ferrule faces left, second ferrule faces right), allowing each to have its light detected independently without interference from adjacent ferrules in the stack.
3Adaptability or versatility
If light redirecting surfaces are added to ferrules, then light routing flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
Light redirecting surfaces with curved or angled geometries are formed on the optical ferrules using precision molding or machining techniques. These curved surfaces efficiently redirect light between fibers while being integrated into the ferrule manufacturing process, balancing optical performance with manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables testing, inspection, and cleaning of optical ferrules without removal, and allows for unobstructed light redirection in stacked configurations by providing a transparent window for light exit and ensuring light is redirected within the connector.
Implementation Method 1
a light redirecting surface configured to receive light along a first direction from an optical fiber received and secured in the groove, and redirect the received light along a different second direction
Data Source
AI summary
An optical connector includes a housing with a bottom wall defining a window therein, and an optical ferrule disposed in the housing and comprising opposing major top and bottom surfaces. The major bottom surface of the optical ferrule faces the bottom wall of the housing. The major top surface includes a groove and a light redirecting surface configured to receive light along a first direction from an optical fiber received and secured in the groove, and redirect the received light along a different second direction. The redirected light exits the optical ferrule though the bottom surface and exits the housing through the window, such that, when the optical connector mates with a mating optical connector including a mating optical ferrule, the mating optical ferrule prevents any of the light exiting the optical ferrule from exiting the housing of the optical connector.